Flooring underlayment with dimple endcaps and related methods

ABSTRACT

An underlayment for installation between a base surface and a flooring material includes (a) a structural membrane formed of a structural material and including a panel and a plurality of dimples projecting from an underside surface of the panel. Each dimple has a dimple tip spaced apart from the underside surface. The underlayment further includes (b) a plurality of discrete dimple endcaps comprising a resilient material. Each endcap is fixed relative to, and covers at least a portion of, the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed.

This application claims the benefit of U.S. Provisional Application Ser. No. 62/667,092, filed May 4, 2018, which is hereby incorporated herein by reference.

FIELD

The specification generally relates to underlayments, and more specifically, to flooring underlayments for installation between a base surface and a flooring material.

BACKGROUND

U.S. Pat. No. 9,869,100 (Sennik) discloses an underlayment for a floor. The underlayment includes a dimpled substrate having a generally planar top side, an opposed bottom side, and a plurality of dimples formed therein. Each dimple is bounded by a dimple wall, and includes a dimple opening along the top side. A smoothing layer is bonded beneficial to the top side of the dimpled substrate and overlays and occludes the dimple openings.

U.S. Pat. App. Pub. No. 2014/0311075 (Cormier et al.) purports to disclose a recoiling energy absorbing system having an upper impact surface that is exposed to percussive impact. An energy absorbing layer is positioned below or inside the upper impact surface. The energy absorbing layer includes one or more thermoformed energy absorbing modules. At least some of the modules are provided with one or more energy absorbing units that extend from an upper platform. Several of the energy absorbing units are provided with a flexible wall that extends from the upper platform. A lateral reinforcement member secures the energy absorbing units to prevent them from splaying. The energy absorbing units at least partially absorb energy generated by an impacting object due to the flexible wall bending inwardly or outwardly and recoiling nondestructively after single or multiple impacts to its un-deflected configuration.

U.S. Pat. App. Pub. No. 2014/0202626 (Sennik) discloses a decoupling assembly for positioning between an underlying surface and a flooring material, the decoupling assembly including a decoupling membrane having a base panel having opposing upper and lower surfaces and a plurality of projections extending from the lower surface for contacting an underlying surface and supporting the base panel above the underlying surface. Each projection includes a bottom surface. The assembly further includes a plurality of adhesive fasteners, each adhesive fastener having an inner surface fixed to the bottom surface of a respective one of the plurality of projections, and an adhesive outer surface opposite the inner surface. The assembly further includes a plurality of release members, each release member covering the outer surface of one respective adhesive fastener, each release member being removable to expose the outer surface of the respective adhesive fastener for adhering the decoupling membrane to the underlying surface.

SUMMARY

The following summary is intended to introduce the reader to various aspects of the applicant's teaching, but not to define any invention.

According to some aspects, an underlayment for installation between a base surface and a flooring material includes: (a) a structural membrane formed of a first, structural material and including a panel having a panel top surface and a panel underside surface opposite the panel top surface. The membrane further includes a plurality of dimples projecting from the panel underside surface for supporting the panel above the base surface. Each dimple has a dimple tip spaced apart from the panel underside surface. The underlayment further includes (b) a plurality of discrete dimple endcaps formed of a second, resilient material, different than the first material. Each dimple endcap is fixed relative to and covers at least a portion of the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed.

In some examples, the endcaps comprise an elastomeric material. In some examples, the elastomeric material comprises a thermoplastic elastomer. In some examples, the panel underside surface is generally free of and unobstructed by the elastomeric material. In some examples, each endcap has an endcap peripheral edge spaced apart from the panel underside surface. In some examples, each dimple includes an endwall spaced apart from the panel underside surface and comprising the dimple tip, and a sidewall extending from the panel to the endwall. Each dimple endcap covers at least a portion of the endwall, and at least a portion of the sidewall is generally free of and unobstructed by the elastomeric material. Each dimple has an outer surface. In some examples, the dimple endcap covers less than 75% of the outer surface. In some examples, each dimple endcap has an endcap thickness measured normal to the outer surface, and the thickness is between about 0.5 mm and 1 mm.

According to some aspects, an underlayment for installation between a base surface and a flooring material includes (a) a structural membrane formed of a structural material and including a panel and a plurality of dimples projecting from an underside surface of the panel. Each dimple has a dimple tip spaced apart from the underside surface. The underlayment further includes (b) a plurality of dimple endcaps formed of a resilient material. Each endcap is fixed relative to and covers at least a portion of the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed. In some examples, the dimple endcaps comprise a thermoplastic elastomer.

According to some aspects, a method of producing an underlayment for installation between a base surface and a flooring material includes: (a) providing a structural membrane having a panel and a plurality of dimples extending from the panel for supporting the panel above the base surface; (b) heating an elastomeric material to form a melt; (c) applying the melt over a tip of each dimple; and (d) solidifying the melt to form a plurality of discrete dimple endcaps. Each dimple endcap is fixed relative to and covers at least a portion of the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed.

In some examples, the elastomeric material comprises a thermoplastic elastomer, and step (b) includes heating the elastomeric material to above a glass transition temperature. In some examples, step (d) includes cooling the melt to below the glass transition temperature.

In some examples, step (c) includes applying the melt over less than 75% of an outer surface of the dimple.

In some examples, step (c) includes passing a roller over each dimple tip, the roller holding the melt.

In some examples, the dimple endcaps are formed with a peripheral edge spaced apart from the panel.

In some examples, the panel is generally free of the melt during steps (c) and (d).

In some examples, the method further includes (e), after step (d), rolling up the underlayment into a roll with at least some of the endcaps directed toward and exposed to the panel top surface.

According to some aspects, a method of producing an underlayment for installation between a base surface and a flooring material includes (a) providing a structural membrane having a panel and a plurality of dimples extending from the panel for supporting the panel above the base surface. The method further includes (b) applying an elastomeric material to a tip of each dimple to form a plurality of discrete dimple endcaps. Each dimple endcap is fixed relative to and covers at least a portion of the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed.

In some examples, the elastomeric material is applied to the tip in one of a liquid and semi-liquid state, and the method further includes solidifying the elastomeric material to form the dimple endcaps.

In some examples, the method includes applying an adhesive to each dimple tip prior to step (b), and step (b) includes dipping the dimple tips into a supply of solid elastomeric granules to adhere the granules to the dimple tips.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the present specification and are not intended to limit the scope of what is taught in any way. In the drawings:

FIG. 1 is a perspective view of a roll of an example underlayment;

FIG. 2 is an elevation view of a portion of the underlayment of FIG. 1 installed between a base and flooring;

FIG. 3 is a cross-sectional view of the underlayment of FIG. 1, taken along line 3-3 of FIG. 2;

FIG. 4 is a flow chart showing an example method of producing the underlayment of FIG. 1; and

FIG. 5 is a schematic showing melt being applied to a substrate of the underlayment of FIG. 1.

DETAILED DESCRIPTION

Various apparatuses or processes will be described below to provide an example of an embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover processes or apparatuses that differ from those described below. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or process described below is not an embodiment of any claimed invention. Any invention disclosed in an apparatus or process described below that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors or owners do not intend to abandon, disclaim, or dedicate to the public any such invention by its disclosure in this document.

Referring to FIG. 1, an example flooring underlayment 100 is shown. A portion of the underlayment 100 is rolled into an underlayment roll 102. The roll 102 can be unrolled for installation of the underlayment 100, as will be described below.

Referring to FIG. 2, in the example illustrated, the underlayment 100 is for installation between a base surface 104 and a flooring material 106. The underlayment 100 can space the flooring material 106 from the base surface 104, and may help protect the flooring material from water, moisture, and/or microbial growth. The underlayment 100 can facilitate drainage of water, may help dampen noise and/or vibration, and/or may help provide cushioning for people walking on the flooring material 106.

The base surface 104 can be, for example, a concrete or wood floor surface in a basement. The flooring material 106 can be a finished flooring material such as, for example, carpet, laminate, engineered hardwood, stone plastic composite (“SPC”) flooring, wood plastic composite (“WPC”) flooring, and/or vinyl flooring. Some types of finished flooring material (e.g. laminate and engineered hardwood) may be installed directly on the underlayment 100, without necessarily requiring the use of an additional subfloor (such as oriented strand board (“OSB”) subflooring or plywood) between the underlayment 100 and the flooring material 106. This may allow for, for example, ease of installation, a decrease in the total flooring height, and/or a decrease in cost.

In the example illustrated, the underlayment 100 includes a structural membrane 108 having a panel 110 and a plurality of dimples 112 projecting from the panel 110 for supporting the panel 110 above the base surface 104. The dimples 112 can help to space the flooring material 106 from the base surface 104, which can provide a number of benefits, for example, facilitating drainage of moisture from between the dimples 112. The membrane 108 can provide structural strength, and in particular compression resistance, to the underlayment 100. The membrane 108 may be made from, for example, polyethylene, high-density polyethylene, polypropylene, and/or another suitable structural plastic or composite. In the example illustrated, the membrane 108 is of integral, unitary, one-piece construction.

In the example illustrated, the panel 110 has a panel top surface 114 and a panel underside surface 116 opposite the panel top surface 114. In the example illustrated, the panel top surface 114 is generally planar and directed toward the flooring material 106 when the underlayment 100 is installed. In the example illustrated, the panel underside surface 116 is generally planar and directed toward the base surface 104 when the underlayment is installed. In the example illustrated, the panel underside surface 116 lies parallel to the base surface 104 when installed, and generally in a horizontal plane.

Referring to FIG. 3, in the example illustrated, the dimples 112 project from the panel underside surface 116. Each dimple 112 has a dimple tip 118 spaced apart from the panel underside surface 116.

In the example illustrated, the underlayment 100 further includes a plurality of dimple endcaps 122. In the example illustrated, each dimple endcap 122 is fixed relative to and covers at least a portion of the dimple tip 118 of a respective dimple 112. In the example illustrated, each dimple endcap 122 covers an entirety of the dimple tip 118. Referring to FIG. 2, the endcaps 122 support the dimples 112 above the base surface 104 when the underlayment 100 is installed. In the example illustrated, the dimple endcaps 122 are formed of a resilient material for resiliently supporting the dimples 112 above the base surface 104.

In the example illustrated, the dimple endcaps 122 comprise an elastomeric material. This may help to, for example, dampen noise and/or vibration. The elastomeric material can comprise, for example, a thermoplastic elastomer (also referred to as thermoplastic rubber) or a thermoset elastomer (also referred to as thermoset rubber). In the example illustrated, the elastomeric material comprises a thermoplastic elastomer. This may facilitate more efficient (e.g. cost effective) production of the underlayment when compared to underlayments utilizing other types of materials, such as, for example, foam layers (e.g. high-density polyethylene foam, polyurethane foam, and/or polypropylene foams). This may also facilitate recycling of the elastomeric material. In some examples, the elastomeric material can have a density greater than 0.50 g/cm³. In some examples, the elastomeric material can have a density greater than 0.80 g/cm³.

In the example illustrated, the dimple endcaps 122 are non-adhesive. This can help simplify manufacturing and packaging of the underlayment by, for example, not making a release member necessary for preventing unintended adhesion of the tips 108 to adjacent surfaces prior to installation. This can also help to provide for easier manipulation and repositioning of the underlayment 100 during installation.

Referring to FIG. 2, in the example illustrated, the endcaps 122 are discrete portions of elastomeric material, the endcaps 122 being isolated from one another and not integrally connected. Each dimple endcap 122 can be a continuous layer of elastomeric material applied in a liquid or semi-liquid state, or in some examples, can be an aggregation of fine elastomeric granules adhered to the dimples in a solid state. In the example illustrated, the panel underside surface 116 is generally free of and unobstructed by the elastomeric material. This can help reduce raw material requirements and facilitate more cost-effective production of the underlayment 100 when compared to underlayments having layers (e.g. foam layers) extending over large portions of the panel underside surface 116. In the example illustrated, each endcap 122 has a peripheral edge 124 spaced apart from the panel underside surface 116.

Referring to FIG. 3, in the example illustrated, each dimple 112 includes a dimple endwall 128 spaced apart from the panel 110 and comprising the dimple tip 118, and a dimple sidewall 130 extending from the panel 110 to the endwall 128. In the example illustrated, each dimple endcap 122 covers at least a portion of the endwall 128 of a respective dimple 112. In the example illustrated, each dimple endcap 122 covers an entirety of the endwall 128. In the example illustrated, each dimple endcap covers at least a portion of the sidewall 130. In the example illustrated, at least a portion of each sidewall 130 is generally free of and unobstructed by the elastomeric material.

In the example illustrated, each dimple 112 has an upper root edge 132 opposite the dimple tip 118 and joined to the panel 110. In the example illustrated, the panel underside surface 116 extends horizontally between the root edges 132 of the dimples 112 when the underlayment 100 is installed. In the example illustrated, the portion of the sidewall 130 extending from the root edge 132 to the dimple endcap 122 is generally free of and unobstructed by the elastomeric material.

Each dimple includes a dimple outer surface 120. In the example illustrated, the outer surface 120 extends from the panel underside surface 116 and comprises the dimple tip 118. In the example illustrated, each endcap 122 is fixed to the outer surface 120 of a respective dimple 112. In some examples, the endcap 122 can cover less than 75% of the outer surface 120. In some examples, the endcap 122 can cover less than 50% of the outer surface 120.

Referring to FIG. 3, in the example illustrated, each dimple endcap 122 has an endcap thickness 134 measured normal to the dimple outer surface 120. The thickness 134 can be between about, for example, 0.5 mm and 5 mm.

In the example illustrated, each dimple 112 includes an interior 136 open to the panel top surface 114. In the example illustrated, the dimple endwall 128 and the dimple sidewall 130 bound the interior 136.

In the example illustrated, the dimple 112 is generally frustoconical. In some examples, the dimple 112 can be another shape, for example, generally frustopyramidal, cubic, cylindrical, or hemispherical.

Referring to FIGS. 4 and 5, in the example illustrated, a method 200 for producing the underlayment 100 is shown. At step 210, the membrane 108 is provided. At step 220, an elastomeric material is heated to form a melt. In the example illustrated, the elastomeric material comprises a thermoplastic elastomer, and the elastomeric material is heated to above a glass transition temperature to form the melt.

At step 230, the melt is applied over the tip 118 of each dimple 112. In the example illustrated, step 230 includes applying the melt over less than 75% of the dimple outer surface 120. In the example illustrated, step 230 includes passing a roller 138 over each dimple tip 118, with the roller 138 holding the melt for application to the dimple tips 118. The thickness of the layer of melt applied to tip 118 of each dimple can be controlled by, for example, controlling the size of the gap between the roller and the tips 118 as the roller passes over the tips. Alternatively or additionally, the thickness of the layer of melt applied to the tips 118 can be controlled by controlling the thickness of the layer of melt on the outer surface of the roller 138 picked up from a supply of melt, for example, from a heated trough. Rotating the roller while holding a blade positioned at a desired spacing from the outer surface of the roller can facilitate achieving a desired thickness of melt on the roller 138 prior to passing the roller 138 over the tips 118 of the dimples.

In an alternate method, step 230 can include dipping the dimple tips 118 into a bath of the melt.

At step 240, the melt is solidified to form the plurality of dimple endcaps 122. In the example illustrated, the elastomeric material comprises a thermoplastic elastomer and step 240 includes cooling the melt to below the glass transition temperature to form the plurality of dimple endcaps 122. In the example illustrated, the dimple endcaps 122 are formed with the peripheral edge 124 spaced apart from the panel 110. In the example illustrated, the panel 110 is generally free of the melt during steps 230 and 240.

In an alternate method, step 240 can include curing the elastomeric material to form the dimple endcaps. In some examples, the curing step can include forming cross-links in the elastomeric material.

In an alternate method, an adhesive can be applied to the tips of the dimples, and the tips can then be dipped in a supply of solid elastomeric granules. The elastomeric granules can be sized in the range of, for example, about 0.5 mm to about 5 mm, and can be presented in a vibratory container to facilitate maintaining a loose, even layer of granules in the container for engagement by the adhesive layer on the dimple tips 118. The container can have a porous or screen-like bottom to allow granule fines or otherwise undersized particles to be evacuated from the supply presented for pick-up by the tips 118.

In the example illustrated, after step 240, the underlayment 100 can optionally be rolled up into the roll 102 (FIG. 1), and the roll 102 can be packaged for shipment. Referring to FIG. 1, in the example illustrated, when the underlayment 100 is in the roll 102, at least some of the endcaps 122 are directed toward and exposed to the panel top surface 114. In some examples, when the underlayment 100 is in the roll 102, at least some of the endcaps 122 can be in direct engagement with the panel top surface 114.

Referring to FIG. 2, in the example illustrated, installation of the underlayment 100 includes unrolling the roll 102 and laying the underlayment 100 on the base surface 104 with the dimple endcaps 122 in engagement with the base surface 104. Optionally, the underlayment 100 is cut into pieces of desired size to cover the base surface 104. Seams between adjacent pieces of underlayment 100 can be secured with, for example, acrylic tape to join the pieces together and maintain moisture barrier properties of the underlayment 100. After the underlayment 100 is laid over the base surface 104, the flooring material 106 is placed over the underlayment 100. In the example illustrated, the flooring material 106 is placed over and supported by the panel top surface 114. In some examples, the flooring material 106 can include a finished flooring material placed directly on the panel top surface 114. In some examples, the flooring material 106 can include a finished flooring material and a subfloor (such as an OSB subfloor or plywood) installed between the underlayment 100 and the finished flooring material. 

1. An underlayment for installation between a base surface and a flooring material, the underlayment comprising: a) a structural membrane formed of a structural material and including a panel having a panel top surface and a panel underside surface opposite the panel top surface, the structural membrane further including a plurality of dimples projecting from the panel underside surface for supporting the panel above the base surface, each dimple having a dimple tip spaced apart from the panel underside surface and a dimple outer surface extending from the panel underside surface to the dimple tip; and b) a plurality of discrete dimple endcaps comprising a resilient material, each dimple endcap fixed to the dimple outer surface and covering the dimple tip of a respective dimple, the endcaps supporting the dimple tips above the base surface when the underlayment is installed.
 2. The underlayment of claim 1, wherein the resilient material comprises an elastomeric material.
 3. The underlayment of claim 1, wherein the resilient material comprises a thermoplastic elastomer.
 4. The underlayment of claim 1, wherein the panel underside surface is generally free of and unobstructed by the resilient material.
 5. The underlayment of claim 1, wherein each endcap has an endcap peripheral edge spaced apart from the panel underside surface.
 6. The underlayment of claim 1, wherein the dimple includes an end wall comprising the dimple tip and a sidewall extending from the panel to the endwall, each dimple endcap covering the endwall, and wherein at least a portion of the sidewall is generally free of and unobstructed by the resilient material.
 7. The underlayment of claim 1, wherein each dimple endcap has an endcap thickness measured normal to the dimple outer surface, and the thickness is between about 0.5 mm and 1 mm.
 8. The underlayment of claim 1, wherein the endcap covers less than 90% of the dimple outer surface.
 9. The underlayment of claim 8, wherein the dimple endcap covers less than 60% of the dimple outer surface.
 10. The underlayment of claim 9, wherein the dimple endcap covers less than 30% of the dimple outer surface.
 11. An underlayment for installation between a base surface and a flooring material, the underlayment comprising: a) a structural membrane formed of a first material and including a panel and a plurality of dimples projecting from an underside surface of the panel, each dimple having a dimple tip spaced apart from the underside surface and a dimple outer surface extending from the panel underside surface to the dimple tip; and b) a plurality of dimple endcaps formed of a second material different than the first material, each endcap fixed to the dimple outer surface and covering the dimple tip of a respective dimple, the endcaps supporting the dimple tips above the base surface when the underlayment is installed.
 12. The underlayment of claim 11, wherein the second material comprises a thermoplastic elastomer.
 13. A method of producing an underlayment for installation between a base surface and a flooring material, the method comprising: a) providing a structural membrane having a panel and a plurality of dimples extending from the panel for supporting the panel above the base surface; b) heating a thermoplastic elastomer to above a glass transition temperature to form an elastomer melt; c) applying the elastomer melt to a tip of each dimple; and d) cooling the elastomer melt to below the glass transition temperature to form a plurality of discrete dimple endcaps, each dimple endcap fixed to the dimple and covering the dimple tip, the endcaps supporting the dimple tips above the base surface when the underlayment is installed.
 14. The method of claim 13, wherein step (c) includes passing a roller over each dimple tip, the roller holding the elastomer melt.
 15. The method of claim 13, wherein the dimple endcaps are formed with a peripheral edge spaced apart from the panel.
 16. The method of claim 13, wherein the panel is generally free of the elastomer melt during steps (c) and (d).
 17. The method of claim 13, further including (d), after step (c), rolling up the underlayment into a roll with at least some of the endcaps directed toward and exposed to the panel top surface. 